Method and apparatus for manufacturing laminates

ABSTRACT

In a method for manufacturing laminates comprising a plurality of continuously formed component members having different cross-sectional shapes, a long-sized workpiece is indexed in the longitudinal direction, the component members having outside contours corresponding to each of the cross-sectional shapes of the laminate are formed with non-separating indentation, with at least part of the outside contours left unseparated from the workpiece, and the component members are sequentially punched out and laminated into one piece in the final stage of indexing of the workpiece.

TECHNICAL FIELD

The present invention relates to a method and apparatus formanufacturing laminates comprising a plurality of continuously formedcomponent members having different cross-sectional shapes.

BACKGROUND ART

FIG. 1 shows diagrams of assistance in explaining a laminate to whichthe present invention is applied; (A) being a front view and (B) a planview. FIG. 2 shows cross-sectional diagrams taken on lines in FIG. 1(A);FIGS. 2(A) through (E) showing cross-sectional views taken on lines A—A,B—B, C—C, D—D and E—E, respectively.

When manufacturing a laminate 100 as shown in FIG. 1 with a steelmaterial, for example, parts having a circular cross section as shown inFIGS. 2(B) and (D) can be turned with a lathe, but the manufacture ofparts having regular tetragonal, orthohexagonal and quasi cruciformcross sections as shown in FIGS. 2(A), (C) and (E) involves extremelycomplicated machining operations requiring great man-hours and time.

It is cumbersome and complicated, or sometimes even totally impossible,to machine a laminate 100 having the aforementioned construction from asold round bar or a block piece. For this reason, there can be a methodof dividing the laminate 100 into a plurality of component members,machining these members, and assembling the machined members into onepiece. If the laminate 100 is of a small size, however, assembling suchmachined members might be impossible.

Casting, for example, is sometimes employed to manufacture theaforementioned laminate 100 having a complex shape. The manufacture ofthe laminate 100 by casting involves multiple processes, such aspreparing a model, forming a casting mold based on the model, andpouring molten metal into the mold, requiring a lot of man-hours andtime.

Even when a precision casting method, including lost-wax process, isemployed, it is difficult to maintain high precision and produce ahighly smooth casting surface. This necessitates finishing the castsurface, leading to increased cost to manufacture the laminate 100.

To solve the abovementioned problem, the present Applicant had alreadyfiled a patent application in Japan for an invention of manufacturinglaminates having multiple cross-sectional shapes by progressivelytransferring (indexing) a hoop-shaped long-sized workpiece in thelongitudinal direction, punching a plurality of component members havingthe contours corresponding to the cross-sectional shapes of thelaminate, temporarily holding the punched component members on thepunched holes of the workpiece by pushback, sequentially stamping outthe component members in the final stage of the indexing of theworkpiece, and assembling the component members into one piece (JapaneseUnexamined Published Patent Application No. Hie-10(1998)-235598).

However, it was found that there still remain some problems in theimprovement patent. That is, since the punched component members aretemporarily held on the punched hole only by frictional force betweenthe member and the hole, the punched component members may sometimescome off from the punched holes due to vibrations during indexing orsome other reasons, interrupting the indexing operation.

Furthermore, the punched component members may be slightly deformed orsubjected to dimensional changes when pushed back to replace to thepunched holes.

The present invention is intended to overcome the aforementionedproblems, and it is an object of the present invention to provide amethod for relatively easily manufacturing laminates by continuouslyforming a plurality of component members having differentcross-sectional shapes.

It is another object of the present invention to provide a method formanufacturing laminates in which the bonding strength of a laminate madeby continuously forming and laminating a plurality of component membershaving different cross-sectional shapes can be easily increased.

It is still another object of the present invention to provide anapparatus for relatively easily manufacturing laminates by continuouslyforming a plurality of component members having differentcross-sectional shapes.

It is a further object of the present invention to provide an apparatusfor manufacturing laminates in which the bonding strength of thelaminate made by continuously forming and laminating a plurality ofcomponent members having different cross-sectional shapes can be easilyincreased.

DISCLOSURE OF THE INVENTION

To achieve these objectives, the method for manufacturing a laminatemade by continuously forming a plurality of component members havingdifferent cross-sectional shapes according to the present inventionemploys the indexing of a long-sized workpiece in the longitudinaldirection, the non-separating indentation of a workpiece into aplurality of component members having contours corresponding to therespective different cross-sectional shapes of the laminate in a statewhere at least part of the contours are left unseparated from theworkpiece, and the sequential stamping out of the component members fromthe workpiece in the final stage of the indexing of the workpiece toassemble them into one piece.

In the above invention, dowel pins and dowel holes are concentricallyprovided on the component members so that the dowel pins are engagedwith the dowel holes on the adjacent component members. In this case,only through holes can be formed on the component member constitutingthe lowest layer.

In the above invention, moreover, a plurality of guide through-holes areprovided on the component members so as to position the componentmembers by engaging guide pins with the guide holes.

In the above invention, moreover, a workpiece on the surface of whichadhesive is deposited can be used. In this case, the adhesive can beprovided in stripes or in bands.

In the above invention, a workpiece on the surface of which a thin filmcontaining lubricant is deposited can be used.

In the method for manufacturing laminates according to the presentinvention where component members having contours corresponding to thecross-sectional shapes of the laminate are formed from a sheet material,and the component members are sequentially and continuously laminatedinto one piece, a long-sized workpiece is progressively transferred(indexed) in the longitudinal direction, clearance holes or projectionsat locations corresponding to the clearance holes are provided withinthe outside contours, the component members having predetermined outsidecontours are formed with the non-separating indentation process in astate where at least part of the contours are left unseparated from theworkpiece, the component members are sequentially stamped out andlaminated in the final stage of the indexing of the workpiece, theprojections are engaged with the clearance holes on the underlyingcomponent members, and the component members are welded to the othernon-adjoining component members to laminate them into one piece.

In the method for manufacturing laminates according to the presentinvention, an irregular-shaped laminate having continuously formeddifferent cross-sectional shapes can be formed by a plurality ofcomponent members having different contours and/or outside dimensions.

In the above method for manufacturing laminates, the projections can beformed in such a manner that h> at (a being a positive integer largerthan 1) when the thickness of the workpiece is t, and the height of theprojections is h.

In the above method for manufacturing laminates, the projections can beformed by burring, or slitting and forming.

In the above method for manufacturing laminates, furthermore, theoutside surface of the projections can be kept electrically unconnectedto the inside surface of the clearance holes.

In the above method for manufacturing laminates, dowel holes and dowelpins are concentrically formed on the upper and lower surface within thecontour so that the adjoining component members can be laminated byengaging the dowel pins with the dowel holes on the component members.

The apparatus for manufacturing laminates continuously formed by aplurality of component members having different cross-sectional shapesaccording to the present invention comprises a feed control device forindexing the workpiece in the longitudinal direction, a plurality ofpunch-die sets disposed in the feeding direction of the workpiece forforming the component members having outside contours corresponding tothe cross-sectional shapes thereof with the non-separating indentationprocess in such a manner that at least part of the outside contours areleft unseparated from the workpiece, and a laminating device provided onthe most downstream side of the punch-die sets in the workpiece feedingdirection for sequentially indenting and laminating the componentmembers into one piece; the punch-die sets adapted to be selectivelyoperable.

The apparatus for manufacturing laminates continuously formed by aplurality of component members having different cross-sectional shapesby forming from a sheet material component members having outsidecontours corresponding to the cross-sectional shapes of the laminate,and sequentially laminating them into one piece according to the presentinvention comprises a feed control device for indexing a long-sizedworkpiece in the longitudinal direction, a plurality of first punch-diesets for forming clearance holes that pass through the abovementionedoutside contours, a plurality of second punch-die sets for forming aplurality of component members with the non-separating indentationprocess in a state where at least part of the outside contours are leftunseparated from the workpiece, and a laminating device provided on themost downstream side of the workpiece in the workpiece feedingdirection; the laminating device comprising a holding device havingholes that allow the component members to pass and adapted to constrainthe downward movement of the workpiece, a pressure-welding deviceprovided above the holding device and equipped with vertically movablepressure-welding electrodes for punching out, laminating andpressure-welding the component members, and a support device providedbelow the holding device and having vertically movable support membersthat can hold the stamped component members; and a selectively operablewelding power supply being connected between the pressure-welding deviceand the support device.

In the apparatus for manufacturing laminates according to the presentinvention, a plurality of laminating devices can be provided in thefeeding direction of the workpiece in such a manner that theselaminating devices can be operated alternately.

Another apparatus for manufacturing laminates continuously formed by aplurality of component members having different cross-sectional shapesby forming from a sheet material component members having outsidecontours corresponding to the cross-sectional shapes of the laminate,and sequentially laminating them into one piece according to the presentinvention comprises a feed control device for indexing a long-sizedworkpiece in the longitudinal direction, a plurality of punch-die setsfor forming a plurality of component members with the non-separatingindentation process in such a manner that at least part of the outsidecontours are left unseparated from the workpiece, and a laminatingdevice provided on the most downstream side of the workpiece forsequentially stamping out and laminating the component members into onepiece; the laminating device comprising a holding device having holesfor allowing the component members to pass and adapted to constrain thedownward movement of the workpiece, a pressure-welding device providedabove the holding device and equipped with vertically movablepressure-welding punches for stamping out, laminating andpressure-welding the component members, a support device provided belowthe holding device and equipped with vertically movable support membersthat can hold the stamped component members; a plurality of thelaminating devices provided in the feeding direction of the workpiece insuch a manner that these laminating devices can be operated alternately.In another apparatus for manufacturing laminates described above, therecan be a construction where every time the component members arelaminated and pressure welded in the pressure-welding device, thesupport members descend by a distance equal to the thickness of thecomponent members and stop at that position.

In another apparatus for manufacturing laminates described above,moreover, punch-die sets can be provided to concentrically form dowelholes and dowel pins each on the upper and lower surfaces of the outsidecontours.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1(A) and 1(B) are diagrams of assistance in explaining a laminateto which the present invention is applied; (A) being a front view and(B) a plan view.

FIGS. 2(A) through 2(E) are cross-sectional views taken on lines A—A,B—B, C—C, D—D and E—E, respectively, in FIG. 1(A).

FIGS. 3(A) through (G) are diagrams of assistance in explaining alaminate and the component members thereof in an embodiment of thepresent invention; (A) and (B) being a front view and a plan view of thelaminate; and (C) through (G) being plan views of the component membersconstituting the laminate.

FIG. 4 is an enlarged longitudinal sectional view showing the componentmembers laminated into one piece in an embodiment of the presentinvention.

FIGS. 5(A) through 5(E) are diagrams of assistance in explaining anotherlaminate and the component members thereof; (A) being a longitudinalsectional view of the laminate, and (B) through (E) being the componentmembers constituting the laminate.

FIG. 6 is a front view illustrating an embodiment of the presentinvention.

FIG. 7 is a side view illustrating an example of the punch-die set inFIG. 6.

FIG. 8 is an enlarged cross-sectional view illustrating an example ofthe non-separating indentation means in an embodiment of the presentinvention.

FIG. 9 is a plan view illustrating the processing of a workpiece in anembodiment of the present invention.

FIG. 10 is an enlarged cross-sectional view illustrating the manner inwhich the workpiece is supported.

FIG. 11 is an enlarged longitudinal sectional view illustrating thestate where component members made from another example of workpiece inan embodiment of the present invention are laminated.

FIG. 12 is a plan view illustrating the state where component membersmade from still another example of workpiece in an embodiment of thepresent invention are laminated.

FIG. 13 is a partially cross-sectional front view of an example of thelaminating device in an embodiment of the present invention.

FIG. 14 is a side view of the construction shown in FIG. 13.

FIG. 15 is an enlarged longitudinal sectional view illustrating anexample of the state where component members are bonded together inanother embodiment of the present invention.

FIG. 16 is an enlarged longitudinal sectional view illustrating anexample of the state where component members are bonded together inanother embodiment of the present invention.

FIG. 17 is an enlarged cross-sectional view illustrating an example ofprojections and clearance holes.

FIG. 18 is a plan view illustrating part of the state where a workpieceis processed in another embodiment of the present invention.

FIG. 19 is a partially cross-sectional front view illustrating anotherexample of the laminating device in an embodiment of the presentinvention.

FIG. 20 is a side view of the construction shown in FIG. 19.

BEST MODE FOR CARRYING OUT THE INVENTION

FIGS. 3(A) through 3(G) are diagrams of assistance in explaining alaminate and the component members thereof in an embodiment of thepresent invention; (A) and (B) being a front view and a plan view of thelaminate; and (C) through (G) being plan views of the component membersconstituting the laminate.

In FIG. 3, a laminate 100 is of essentially the same shape as that shownin FIG. 1, and formed by laminating a plurality (two in FIG. 3) each ofmultiple types of component members 101˜105 having outside contourscorresponding to the cross-sectional shapes at each position in theheight direction into one piece.

Numeral 106 refers to dowel holes (or blind holes) formed into the sameshape and dimensions at the central part on the flat surface of thecomponent members 101˜105 at the same relative positions with means aswill be described later. The number of component members 101˜105 may beonly one, or three or more, depending on the shape and dimensions of thelaminate 100.

FIG. 4 is an enlarged longitudinal sectional view illustrating anexample of laminating component members into one piece in an embodimentof the present invention. Like parts are indicated by like referencenumerals as used in FIG. 3.

In FIG. 4, numeral 107 refers to dowel pins formed concentrically withthe dowel holes 106. The dowel holes 106 and the dowel pins 107 can beformed with a punch and die having a circular cross-sectional shape bymaking the penetration depth d of the punch into the die smaller thanthe thickness t of the component members 103˜105 (same applies to thecomponent members 101 and 102 in FIG. 3). The dowel holes 106 and thedowel pins 107 may be formed either simultaneously with the punching ofthe component members 101˜105 in FIG. 3 from a steel sheet, for example,using punch-die sets, or in any of appropriate processes different fromthe punching process of the component members 101˜105.

The component members 101˜105 formed in the aforementioned manner can besequentially laminated into one piece by engaging the dowel pins 107with the dowel holes 106 on the adjoining component members as shown inFIG. 4.

In this case, the dowel holes 106 and the dowel pins 107 can be servedas positioning means for lamination since the dowel holes 106 and thedowel pins 107 are formed into the same shape and dimensions andprovided at the central part of the component members 101˜105 at thesame relative positions.

The dowel pins 107 need not be provided on the component member 105 atthe lowest layer, and through holes 106 a should preferably be providedinstead. By sequentially laminating the component members 101˜105 in theaforementioned manner, the laminate 100 as shown in FIGS. 3(A) and 3(B)can be manufactured.

FIGS. 5(A) through 5(E) are diagrams of assistance in explaining anotherlaminate and the component members thereof in an embodiment of thepresent invention; (A) being a longitudinal sectional view of thelaminate, and (B) through (E) being plan views of the component membersconstituting the laminate, respectively. The laminate 200 in FIG. 5 ismanufactured by punching component members 201˜204 from a steel sheet,for example, with punch-die sets, and laminating them into one piece, asin the case with the laminate shown in FIG. 3.

In FIG. 5, numeral 205 refers to dowel holes formed on the top surfaceof the component members 201˜204, and dowel pins (not shown) areconcentrically formed on the bottom surface thereof in the same manneras those shown in FIG. 4. Numeral 206 refers to guide holes formedpassing through the component members 201˜204 so that the positioningaccuracy of the component members 201˜204 can be improved by engagingthe guide holes with guide pins provided upright on the laminatingdevice during laminating and pressure-welding operations. Numeral 207refers to a round hole, 208 to a spline hole, both formed passingthrough the central part of the component members 202˜204.

A laminate 200 is formed by sequentially laminating the componentmembers 201˜204 formed in the aforementioned manner into one piece, asshown in FIG. 5(A). That is, gear parts can be formed on the outercircumferential surface of the component members 202 and 204, and a campart on the outer circumferential surface of the component member 203,respectively; with a spacer part provided between the cam and gearparts. The outer circumferential surfaces of the cam and gear parts areaccurately positioned and formed with high precision, capable of fullyperforming their respective functions since positioning accuracy can beimproved by not only engaging the dowel pins (not shown) of thecomponent members 201˜204 with the dowel holes thereof, but alsoengaging the guide pins with the guide holes 206.

FIG. 6 is a front view showing an embodiment of the present invention.

In FIG. 6, numeral 1 refers to a feeding device, 2 to a punch-die set,and 5 to a laminating device, disposed in this order in the feedingdirection of the workpiece 4. That is, the feeding device 1, disposed onthe most upstream side of the feeding direction of the workpiece 4, isconstructed so as to index in the longitudinal direction the workpiece 4coiled into a hoop. Note that the feeding device 1 may be provided onthe downstream side of the laminating device 5, or between the basemachines 3 and 3, which will be described later.

The punch-die set 2 has an after-mentioned construction, and is disposedat intervals of mP (m being a given positive integer, and P being afeeding pitch of the workpiece 4). A plurality of punch-die sets 2(three sets in FIG. 6) are provided in the base machine 3, for example,and have such a construction that each punch-die set 2 can be positionedin the feeding direction of the workpiece 4 and operated selectively.These punch-die sets 2 are provided corresponding to the types of thecomponent members so that component members as shown in FIGS. 2 and 5can be formed. In this case, an appropriate number of the base machines3 having a plurality of punch-die sets 2 can be provided in tandem inthe feeding direction of the workpiece 4.

The laminating device 5 is provided on the most downstream side in thefeeding direction of the workpiece 4 at intervals nP (n being a givenpositive integer) and comprises a base 51, a holding device 52, asupport device 53 and a pressure-welding device 54.

The holding device has a holding plate 56 having a hole 55 forconstraining the downward movement of the workpiece 4 and allowing thecomponent members (not shown. As indicated by each of the numerals101˜105 in FIG. 3, for example) to pass, and a guide member 57 formed insuch a manner as to press and release the workpiece 4. The supportdevice 53 provided below the holding device 52 is formed in such amanner that the aforementioned component members and the laminate 100are placed on the support device 53.

On the pressure-welding device 54 provided above the holding device 52provided is a pressure-welding punch 58 vertically movably formed sothat the component members can be punched out from the workpiece,laminated and pressure welded. Multiple types of the pressure-weldingdevices 58 having outside contours similar to, or corresponding to theoutside contours of the aforementioned component members are provided ona holder 59 so that a predetermined pressure-welding punch 58 can beselectively placed immediately above the workpiece 4 by rotating theholder 59 around the vertical axis thereof.

Numeral 60 refers to an actuating device comprising a hydrauliccylinder, for example, to cause the pressure-welding punch 58 to come incontact with, or detach from, the workpiece 4 via a column 61 and asupport plate 62 provided on the base 51.

FIG. 7 is a side view illustrating an example of the punch-die set inFIG. 6.

In FIG. 7, numeral 21 refers to a punch-die set proper, formed of asteel material, for example, into an approximately U shape, having anintegrally formed dovetail 22 on the lower end thereof to engage with adovetail groove 23 provided on the base 20 so that the position of theset proper 21 can be moved and adjusted in the feeding direction (in thedirection vertical to the page) of the workpiece 4, and the movement ofthe set proper 21 in the direction vertical to the feeding direction,that is, in the horizontal direction in FIG. 7, can be constrained. Oncepositioned, the set proper 21 is held in position on the base 20 by aclamp device 24. The punch-die set 2 may be a gate-type set propercomprising an upper and lower ones connected with four guide bars.

Numeral 25 refers to a cassette formed of a steel material, for example,into an approximately U shape, with a punch 26 vertically movablyprovided on the upper part thereof and a die 27 provided on the lowerpart thereof at a position facing the punch 26. The cassette 25 isdetachably provided on the set proper 21. Numeral 28 refers to a clampscrew for fixedly fitting the cassette 25 to the set proper 21. Numeral29 refers to a hydraulic cylinder provided on the upper end of the setproper 21 to cause the punch 26 to be operated via an actuating rod 30.

FIG. 8 is an enlarged cross-sectional view illustrating an example ofnon-separating indentation means in an embodiment of the presentinvention. Like parts are indicated by like numerals in FIGS. 4 and 7.Component members are indicated by numeral 104.

In FIG. 8, numeral 31 refers to a stripper for forcing the workpiece 4in place on the surface of the die 27 before and after the actuation ofthe punch 26.

Numeral 32 refers to non-separating indentation means, provided in thedie 27, comprising a vertically movably formed receiving member 33, anda compression spring 34 for upwardly preloading the receiving member 33.As means for energizing the receiving member 33, drive means such as ahydraulic cylinder may be used. In such a case, the upper end of thereceiving member 33 should be held at a position (d-ä) away from theupper end of the die 27. That is, with the thickness d of the workpiece4, ä is set to ä=0.1˜0.2 mm, including the amount of compressiondeformation of the workpiece 4.

With the aforementioned construction, when the punch 26 descends whilethe workpiece 4 is kept forced onto the upper surface of the die 27 withthe stripper, as shown in FIG. 8, the component member 104 is indented,causing the receiving member 33 to descend down to the lower limitthereof. In this case, the component member 104 is subjected to theso-called non-separating indentation process where the component member104 remains not completely punched out of the workpiece 4, with theoutside contour thereof connected to the workpiece 4 via connectingparts 104 a of a very small thickness δ, for example.

The connecting parts 104 a may of course be formed over the entireoutside contour of the component member 104, but should be formed atleast part of the outside contour of the component member 104 byselecting the shape of the punch 26 appropriately.

After the punch 26 is lifted, the component member 104 is pushedupwards, together with the workpiece 4, from the die 27 by the upwardpreloading force of the compression spring 34 as the stripper 31 islifted. The component member 104 is then transported to the final stage,while left connected to the workpiece 4, as the workpiece 4 is indexed.

FIG. 9 is a plan view showing the state where the workpiece is processedin an embodiment of the present invention to produce component members101˜105 for manufacturing the laminate 100 shown in FIG. 3.

In FIG. 9, the workpiece 4 is indexed at intervals of P in the directionshown by arrows by the feeding device shown in FIG. 6. Numeral 6 refersto pilot holes provided on the workpiece 4 at intervals of P on the mostupstream side of the punch-die set 2 shown in FIG. 6 to serve asreference holes for positioning in the subsequent processes.

With the punch-die set 2 similar to that described above, dowel holes106 are processed, and dowel pins (not shown. Refer to numeral 107 inFIG. 4) are also provided concentrically with the dowel holes 106. Inthis case, pilot pins for engaging with the pilot holes 6 are providedon the punch-die set 2 for subsequent processing with the punch-die set2 by positioning the workpiece 4 using the pilot holes 6 as reference(same applies to the punch-die sets in the succeeding processes). Bysequentially indexing the workpiece 4, moreover, component members101˜105 are processed with the non-separating indentation process, asshown in FIG. 8. In this case, the punch-die sets 2 as shown in FIG. 6having five types of punches and dies corresponding to the outsidecontours of the component members 101˜105 are disposed in such a mannerthat these punch-die sets 2 can be operated selectively. Two pieces, forexample, each of the component members 101˜105 corresponding to thelaminate 100 shown in FIG. 3 are formed and sequentially subjected toprocessing and transported to the final stage.

The component members 101˜105 formed on the workpiece 4 with thenon-separating indentation process as described above are transported tothe laminating device 5 provided in the final stage in FIG. 6, andsequentially laminated in the order from the component member 105 to 101into one piece. That is, as the guide member 57 descends, and the pilotpins are engaged with the pilot holes 6 on the workpiece 4 to positionand force the workpiece 4 in place, the actuating device 60 is operatedto sequentially punch out the component members 101˜105 completely fromthe workpiece 4 via an actuating member 63 and the pressure-weldingpunch 58 (by cutting off the connecting parts 104 a of a very smallthickness in FIG. 8), and placed on the support device 53.

In this case, the component members 101˜105 are easily punched out andlaminated into one piece by the pressure-welding punch 58 since thecomponent members 101˜105 are connected to the workpiece 4 via theconnecting parts 104 a of a very small thickness, as shown in FIG. 8,and the adjoining component members are laminated together as the dowelpins 107 are engaged with the dowel holes 106, as shown in FIG. 4.

Since the hole 55 provided on the holding plate 56 of the holding device52 is formed larger than the maximum outside contours of the componentmembers 101˜105, any of the component members 101˜105 can be passedthrough the hole 55. The support device 53 for supporting the componentmembers 101˜105 should preferably be constructed in such a manner thatas the component members 101˜105 are laminated and pressure welded withthe pressure-welding punch 58, the support device 53 can descend by theamount of the thickness of the component members 101˜105 and stop atthat position. After having been formed in the aforementioned manner,the laminate 100 shown in FIG. 3 is discharged from the support device53, and the next laminating and pressure-welding operations arerepeated.

FIG. 10 is an enlarged cross-sectional view showing the state where theworkpiece is supported. In the present invention, the component member104 formed with the non-separating indentation process protrudes atleast by d-δ towards the lower surface of the workpiece 4, as shown inFIG. 8, posing a problem of the protruded part interfering with thecomponent of the device during transportation of the workpiece 4. Theworkpiece 4 must therefore be transported in a suspended state, as shownin FIG. 10.

In FIG. 10, numeral 40 refers to a base plate that is shown as a typicalcomponent of the punch-die set or the laminating device facing theworkpiece 4. Numeral 41 refers to a guide pin mounted in a verticallymovable manner and preloaded upward by a spring 42. A groove 43 isprovided in the vicinity of the upper end of the guide pin 41; the widthof the groove 43 being formed slightly larger than the thickness of theworkpiece 4 to facilitate the movement of the workpiece 4.

With the aforementioned construction, the workpiece 4 is kept in asuspended state during transportation, as shown in FIG. 10, while duringthe operation of the device, the guide pin 41 descends as the actuatingmember of the device descends, and is returned upward by the spring 42after the operation.

FIG. 11 is an enlarged longitudinal sectional view showing the statewhere the component members made of another example of the workpiece arelaminated in an embodiment of the present invention.

In FIG. 11, numeral 10 refers to adhesive applied between the componentmembers 101 and 101, for example to tightly bond the component membersduring lamination and pressure-welding, or during heat treatment afterlamination. To achieve this laminated state, a workpiece the surface ofwhich is coated in advance with an adhesive or a thermo-compressionsheet of a thickness of 10˜50 μm can be used.

FIG. 12 is a plan view showing another example that is an alternative tothe example shown in FIG. 11 where the adhesive is deposited over theentire surface.

The hatched portion in FIG. 12 shows the adhesive applied to the surfaceof the workpiece 4 in stripes or bands. When the laminate 200 as shownin FIG. 5, for example, is formed using this workpiece 4 having stripesor bands of adhesive, very small gaps are formed between the adhesiveapplied in stripes or bands. Thus, the gears, cams or other parts of thelaminate 200 can be lubricated by spreading or storing a lubricantbetween these very small gaps. It may be effective for the lubricationof the laminate 200 to use the workpiece 4 on the surface of which athin film containing a lubricant such as fine powders of carbon, forexample, is deposited.

FIG. 13 is a partially cross-sectional front view showing an example ofthe laminating device in an embodiment of the present invention, andFIG. 14 is a side view of the construction shown in FIG. 13. Like partsare indicated by like numerals used in FIG. 6.

In FIGS. 13 and 14, two sets, for example, of the laminating device 5are disposed at intervals of nP with the punch-die set 2 on the mostdownstream side in the feeding direction of the workpiece 4, as shown inFIG. 6. Intervals of the laminating devices 5 and 5 are set to sP (sbeing a given positive integer), and the s value should preferably be assmall as possible.

A material guide 64 is vertically movably provided on the holding plate56 in such a manner that the material guide 64 is engaged with thelongitudinal edge of the workpiece 4 while allowing the longitudinalmovement of the workpiece 4 and constraining the movement of theworkpiece 4 in the direction orthogonal to the feeding direction.

Now, the construction of the support device 53 will be described in thefollowing. The entire support device 53 is supported in the base 51 by asupport rod 70 and a support plate 71 provided on the base 51.

Numeral 72 is a pedestal supported by a guide bar 73 provided passingthrough the base 51, a guide plate 74 and a support shaft 76 providedupright on the support plate 71 and having a male screw 75. Numeral 77refers to a female screw member provided on the guide plate 74 andscrewed to the male thread 75. The male and female screws 75 and 77should preferably be of multithread to have a maximum lead.

Numeral 78 refers to a disc fixedly fitted to the support shaft 76 belowthe support plate 71, constituting a disc brake 82 by being selectivelypressed by a cylinder (not shown) provided by a caliper 81 provided onthe base 51 so that the rotation of the support shaft 76 can be brakedor released.

Numeral 80 refers to a drive motor provided on the support plate 71 viaa mounting plate to drive the support shaft 76 in forward and backwarddirections. Numeral 79 refers to a bearing to support the lower end ofthe support shaft 76.

With the aforementioned construction, when the workpiece 4 on which thecomponent members 101˜105 shown in FIG. 3 are formed with thenon-separating indentation process by selectively operating a pluralityof punch-die sets shown in FIG. 7 is transported onto one laminatingdevice 5 shown in FIGS. 13 and 14 as the final stage, the material guide64 descends, forcing the workpiece 4 in place on the holding plate 56.

Next, the pressure-welding device 54 is driven by actuating theactuating device 60 to punch out a component member from the workpiece 4and place them on the pedestal 72 constituting the support device 53.After the pressure-welding punch 58 is retracted upwards, the workpiece4 is indexed by one pitch P, and the next component member is punchedout from the workpiece 4 on the preceding component member in the samemanner as the foregoing, and laminated and pressure welded. By actuatingthe pressure-welding punch 58, and engaging the dowel holes 106 shown inFIG. 4 with the dowel pins 107, the adjoining component members aretightly laminated and pressure welded.

When the component members are laminated and pressure welded with thepressure-welding punch 58, the drive motor 80 is left inactive, but thepedestal 72 can be stopped at that position by putting the disc brake 82into a braking state. By the pushing force exerted by thepressure-welding punch 58 when laminating and pressure-welding thecomponent members, the male screw engaged with the female screw iscaused to rotate via the female screw resisting the braking force of thedisc brake 82, and the pedestal 72 descends by the amount equal to thethickness of a component member, and stops at that position. That is, bymaking the pushing force of the pressure-welding punch 58 larger thanthe braking force of the disc brake 82, the pedestal 72 on which thecomponent members are placed can repeat sequential descending and stopoperations to laminate a predetermined number of component members intoone piece to form a laminate 100.

After the laminate 100 has been formed in the foregoing manner, thepressure-welding punch 58 can be lifted by actuating the actuatingdevice 60, and the laminate 100 can be discharged via a dischargingchute 86 (refer to FIG. 14) by actuating a discharging device 85. Afterthe laminate 100 has been discharged from the pedestal 72, the drivemotor 80 is operated in a state where the disc brake 82 is released torotate the support shaft 76, thereby causing the pedestal 72 to ascendto a place immediately beneath the holding plate 56 (refer to FIG. 13).The drive motor 80 is then stopped, bringing the disc brake 82 to abraking state to hold the pedestal 72 at that position. Thus, thepedestal 72 is ready to receive the next component member, and theforegoing operations are repeated.

Since the indexing of the workpiece 4 and the processing with thepunch-die sets 2 cannot be performed in a laminating device 5 so long asthe laminate 100 is discharged and the pedestal 72 is returned to theoriginal position, another laminating device 5 is operated. Thus, theworkpiece 4 can be continuously processed without interruption.

That is, by operating the two laminating devices provided in the feedingdirection of the workpiece 4, the entire equipment can be continuouslyoperating with improved processing efficiency (though both the devicesmay be temporarily operated simultaneously when operation is shiftedfrom a laminating device 5 on the downstream side in the feedingdirection of the workpiece 4 to another laminating device 5 on theupstream side).

More than two laminating devices 5 can be provided to permit them to beoperated alternately, taking into consideration processing time andother factors in the laminating device 5.

FIGS. 15 and 16 are enlarged longitudinal sectional views showingexamples of the state where the component members are bonded together inanother embodiment of the present invention. In FIGS. 15 and 16,description is limited to the component member 201, but same applies tothe other component members 202˜204.

In FIG. 15, numeral 209 refers to a dowel pin formed concentrically withthe dowel hole 205. Numeral 210 refers to a projection formed withburring in such a manner as to protrude towards the lower part of thecomponent member 201. The projection 210 is formed into a hollowcylindrical shape, for example, with the outside diameter being d andthe height h, in such a fashion that h=t+α, i.e., h>t where α is awelding allowance set to a size enough to form a weld during welding,which will be described later. The welding allowance α can be determinedappropriately, depending on the material, thickness t of the componentmember 201 and the height of the projection. As welding means, spotwelding, resistance welding, brazing or other appropriate means can beused.

Numeral 211 is a clearance hole formed passing through the componentmember 201 at a location corresponding to the projection 210. Theclearance hole 211 is formed into a round shape, for example, in such afashion that D>d where D is the inside diameter, so that the outsidesurface of the projection 210 is not electrically connected to theinside surface of the clearance hole 211 when the component member 201is laminated, as will be described later. More specifically, anon-contact state, that is, a gap of more than 0.2 mm, for example, ismaintained between the outside surface of the projection 211 and theinside surface of the clearance hole 211. Note that only a dowel throughhole 205 a is provided on the component member 201 a constituting thelowest layer, and neither a projection 210 nor a clearance hole 211 isformed on it.

With the aforementioned construction, a component member 201 a and acomponent member 201 having a clearance hole 211 can be laminated intoone piece by placing the component member 201 a on the pedestal 212 madeof an electrically conductive material, positioning the component member201 having the clearance hole 211 by engaging the dowel hole 205 a withthe dowel pins 209, and pressure-welding both via the pressure-weldingelectrode 213, as shown in FIG. 16.

Next, another component member 201 having a projection 210 can be weldedby positioning the component member 201 by engaging the dowel hole 205with the dowel pin 209, pressing the component member 201 via thepressure-welding electrode 213 in such a manner that the tip of theprojection 210 passes through the clearance hole 211 on the underlyingcomponent member 201 and comes in contact with the other componentmember 201 that is in a non-contact state, and feeding a current from awelding power supply 214 between the pressure-welding electrode 213 andthe pedestal 212 to form a weld 215 at the tip of the projection 210.

With the construction shown in FIG. 15, five component members 201 canbe tightly bonded together, as shown in FIG. 16, by positioning thecomponent member 201 having the projection 210 by engaging the dowelhole 205 with the dowel pin 209, pressing the component member 201 viathe pressure-welding electrode 213 in such a manner that the tip of theprojection 210 passes through the clearance hole 211 on the underlyingcomponent member 201 and comes in contact with the other componentmember 201 that is in a non-contact state, and feeding a current from awelding power supply 214 between the pressure-welding electrode 213 andthe pedestal 212 to form a weld 215.

In FIGS. 15 and 16, an example where a component member 201 having aclearance hole 211 and a component member 211 having a projection 210are laminated alternately is shown. A plurality of component members 201having clearance holes 211 may be laminated consecutively. In such acase, the height h of the projection 210 is set to a value such that h>at (a being a positive integer larger than 1). That is, the height h ofthe projection 210 may be set appropriately, depending on the number ofcomponent members to be laminated consecutively.

The pressure-welding electrode 213 is naturally made of an electricallyconductive material, and should have such a construction that electriccurrent can be fed intensively to the projection at which welding isperformed, and be equipped with appropriate cooling means since arelatively large current flows therein.

FIG. 17 is an enlarged cross-sectional view showing another example ofthe projection and the clearance hole.

In FIG. 17, the projection 210 is formed by slitting and forming into anL-shaped lug, while the clearance hole 211 is formed into a slottedhole. With this construction, not only the aforementioned operations canbe achieved, but also the weight of the component member 201 can bereduced, particularly suitable for component members for which weightreduction is required. Aside from those described above, the projection210 and the clearance hole 211 can be of various shapes.

FIG. 18 is a plan view showing part of the state where the workpiece isprocessed in another embodiment of the present invention, that is, partof the component members 201˜204 for manufacturing the laminate 200shown in FIG. 5.

In FIG. 18, the workpiece 4 is indexed at predetermined intervals of Pby the feeding device shown in FIG. 6. Numeral 6 refers to pilot holesthat are processed regularly on the workpiece 4 at intervals P by thepunch-die set 2 on the most upstream side shown in FIG. 6 and serve asreference holes for positioning in the subsequent processes.

Next, the dowel holes 205 and dowel pins (not shown. Refer to numeral209 in FIG. 15.) that are concentric with the dowel holes 205 are formedwith the punch-die set 2 as described above. In this case, pilot pinsengaging with the pilot holes 6 are provided on the punch-die set 2 sothat the punch-die set 2 is positioned using the pilot holes 6 asreference holes (same applies to the punch-die sets in the subsequentprocesses.)

Next, the projections 210 and the clearance holes 211 are selectivelyprocessed as the workpiece 4 is sequentially indexed at intervals of P.In this case, the projections 210 and the clearance holes 211 arealternately processed for a laminate formed by alternately laminatingcomponent members 210˜204, whereas the clearance holes 211 are processedconsecutively for a laminate formed by consecutively laminating aplurality of the component members. Thereafter, a predetermined numberof round holes 207 are processed consecutively on the component member201, and a predetermined number of spline holes are processedconsecutively on the component members 202˜204. The outside contours ofthe component members 201˜204 are processed with the non-separatingindentation process as the workpiece 4 is sequentially indexed atintervals of P.

To carry out the aforementioned indexed processing, six types ofpunch-die sets corresponding to the round holes 207, the spline holes208, and the outside contours of the component members 201˜204 aredisposed, in addition to the punch-die sets (to be operated at alltimes) having punches and dies for processing the pilot holes 6, thedowel holes 205 and the dowel pins 209; these punch-die sets adapted tobe selectively operable. With this arrangement, six pieces each of thecomponent members 201 and five each of the component members 202˜204corresponding to the laminate 200 shown in FIG. 5, for example, areformed and transported to the final stage, together with the workpiece4.

The component members 201˜204 processed on the workpiece 4 with thenon-separating indentation process in this way are transported to thelaminating device provided in the final stage in FIG. 6, and aresequentially laminated in the order of the component members 204 through201, with the component member 201 interposed therebetween. That is, asthe guide member 57 descends, the pilot pins are engaged with the pilotholes 6 on the workpiece 4 for positioning, and then the componentmembers 201˜204 are sequentially punched out from the workpiece 4 viathe actuating member 63 and the pressure-welding punch 58 by actuatingthe actuating device 60 and placed on the support device 53.

The laminating device used in this case requires to have a welding powersupply, as shown in FIGS. 19 and 20. That is, FIG. 19 is a partiallycross-sectional front view showing another example of the laminatingdevice in an embodiment of the present invention, and FIG. 20 is a sideview of the construction shown in FIG. 19. Like parts are indicated bylike numerals used in FIGS. 13 and 14.

In FIGS. 19 and 20, a vertically movable pressure-welding electrode 58 ais provided on the pressure-welding device 54 to punch out the componentmembers from the workpiece 4. The pressure-welding electrode 58 a ismade of an electrically conductive material, and fixedly fitted to theactuating member 63 via a spacer made of an insulating material. Numeral65 is a welding power supply connected between the pressure-weldingelectrode 58 a and the support device 53, adapted to selectivelyoperable.

When punching out the component members 201˜204, the component members201˜204 are guided by a connecting part 104 a (refer to FIG. 8) formedon the workpiece 4 and laminated into one piece since the dowel holes205 are engaged with the dowel pins 209 on the adjoining componentmembers, as shown in FIG. 15, and a weld 215 is formed at the tip of theprojection 210.

Since the hole 55 provided on the holding plate 56 on the holding device52 is formed larger than the maximum outside contours of the componentmembers 201˜204, any of the component members 201˜204 can be passedthrough the hole without hindrance.

The support device 53 for supporting the component members 201˜204should preferably be such that the support device 53 descends by theamount of the thickness of the component members 201˜204 and stops atthat position every time the component members 201˜204 are laminated andpressure welded by the pressure-welding electrode 58 a.

After the laminate 200 shown in FIG. 5 is formed in the aforementionedmanner, the laminate 200 is discharged from the support device 53, andthe next laminating and pressure-welding operations are repeated. Thecontinuous operation of the entire device by installing a plurality ofthe laminating devices 5 is similar to the aforementioned embodiment.

In the aforementioned embodiments, description has been made about thepositioning of the component members by engaging the dowel holes withthe dowel pins. The present invention, however, is not limited to it,but positioning can be accomplished by providing guide holes passingthrough the outside contours of the component members and engaging theguide holes with the guide pins for lamination, or engaging the outsidecontours of the component members with the guide pins.

Industrial Applicability

The present invention having the aforementioned construction andoperation can achieve the following beneficial effects.

-   (1) Even complex laminates that cannot be processed with normal    machining operations can be manufactured relatively easily.-   (2) Any local changes to the specification of the laminate can be    quickly coped with by changing part of the component members. This    enables limited production of diversified products.-   (3) Despite the lamination of sheet materials, the component members    can be tightly bonded together, making it possible to manufacture    highly functional laminates. By welding the component members, the    bonding strength of the component members can be improved.-   (4) Since multiple types of component members are formed with the    non-separating indentation process without punched out from the    workpiece, and transported together with a long-sized workpiece, or    multiple types of component members are manufactured with indexed    processing, together with the long-sized workpiece, processes and    parts can be easily controlled, enabling highly efficient, low-cost    production through integrated production starting from raw material.-   (5) By providing a plurality of laminating devices and operating    them alternately, the entire device can be operated continuously    without interrupting the processing of the workpiece. This leads to    substantially improved processing efficiency.

1. A method for sequentially manufacturing component members havingdifferent shapes comprising indexing a long-sized workpiece in thelongitudinal direction, indexing the component members having differentshapes after the outside contours thereof have been formed withnon-separating indentation with at least part of the outside contoursthereof left unseparated from the workpiece, and separating each of thecomponent members from the workpiece in the final stage of indexing ofthe workpiece.
 2. A method for manufacturing laminates comprising aplurality of continuously formed component members having differentcross-sectional shapes comprising indexing a long-sized workpiece in thelongitudinal direction, forming the component members having differentoutside contours corresponding to each of the cross-sectional shapes ofthe laminate with non-separating indentation, with at least part of theoutside contours thereof left unseparated from the workpiece, andsequentially punching out the component members from the workpiece andlaminating the component members into one piece in the final stage ofindexing of the workpiece.
 3. A method for manufacturing laminates asset forth in claim 2 wherein dowel pins and dowel holes are formedconcentrically on the component members, and the dowel pins are engagedwith the dowel holes on the adjoining component members.
 4. A method formanufacturing laminates as set forth in claim 3 wherein a through holeis formed on the component member on the lowest layer.
 5. A methodmanufacturing laminates as set forth in claim 2 wherein a plurality ofguide through holes are formed on the component members, and thecomponent members are positioned by engaging the guide pins with guideholes in the final stage of indexing.
 6. A method for manufacturinglaminates as set forth in claim 2 wherein a workpiece on the surface ofwhich adhesive is deposited is used.
 7. A method for manufacturinglaminates as set forth in claim 6 wherein the adhesive is deposited instripes or bands.
 8. A method for manufacturing laminates as set forthin claim 2, wherein a workpiece on the surface of which a thin filmcontaining lubricant is deposited is used.
 9. A method for manufacturinglaminates comprising a plurality of continuously formed componentmembers having different cross-sectional shapes; the component membershaving outside contours corresponding to the cross-sectional shapes ofthe laminate being formed from a sheet material and sequentiallylaminated into one piece comprising indexing a long-sized workpiece inthe longitudinal direction, forming clearance holes within the outsidecontours of the component members, or projections at locationscorresponding to the clearance holes, forming the component membershaving predetermined outside contours with non-separating indentation,with at least part of the outside contours left unseparated from theworkpiece, sequentially punching out the component members from theworkpiece and laminating the component members into one piece in thefinal stage of indexing of the workpiece, and causing the projections topass through the clearance holes on the underlying component member andwelding the component member with the non-adjoining component memberinto one piece.
 10. A method for manufacturing laminates as set forth inclaim 9 wherein an irregular-shaped laminate having differentcross-sectional shapes comprising continuously formed component membershaving different outside contours and/or outside dimensions is formed.11. A method for manufacturing laminates as set forth in claim 9 whereinthe projections are formed in such a manner that h>a (a being a positiveinteger larger than 1) when the thickness of the workpiece is t, and theheight of the projections is h.
 12. A method for manufacturing laminatesas set forth in claim 9 wherein the projections are formed with burringor slitting and forming operation.
 13. A method for manufacturinglaminates as set forth in claim 9 wherein the outside surface of theprojections is kept electrically unconnected to the inside surface ofthe clearance holes.
 14. A method for manufacturing laminates as setforth in claim 9 wherein dowel holes and dowel pins are formedconcentrically on the upper and lower surfaces within the outsidecontours of the component members, and the adjoining component membersare laminated by engaging the dowel holes with the dowel pins thereof.15. An apparatus for manufacturing laminates comprising a plurality ofcontinuously formed component members having different cross-sectionalshapes comprising a feeding device for indexing a long-sized workpiecein the longitudinal direction, a plurality of punch-die sets disposed inthe feeding direction of the workpiece for forming multiple types ofcomponent members having outside contours corresponding to each of thecross-sectional shapes of the laminate with non-separating indentation,with at least part of the outside contours left unseparated from theworkpiece, and a laminating device disposed on the most downstream sideof the punch-die sets in the feeding direction of the workpiece forsequentially punching out the component members from the workpiece andlaminating the component members into one piece; the punch-die setsbeing selectively operable.
 16. An apparatus for manufacturing laminatescomprising continuously formed component members having differentcross-sectional shapes; the component members having outside contourscorresponding to the cross-sectional shapes of the laminate being formedfrom a sheet material and sequentially laminated into one piececomprising a feeding device for indexing a long-sized workpiece in thelongitudinal direction, a plurality of first punch-die sets forclearance holes passing through the outside contours or projection, aplurality of second punch-die sets for a plurality of the componentmembers with non-separating indentation, with at least part of theoutside contours left unseparated from the workpiece, and a laminatingdevice disposed on the most downstream side in the feeding direction ofthe workpiece; the laminating device comprising a holding device havinga hole for allowing the component members to pass and formed in such amanner as to constrain the downward movement of the workpiece, apressure-welding device disposed above the holding device and having avertically movable pressure-welding electrode for punching out,laminating and pressure-welding the component members, and a supportdevice provided below the holding device and having a vertically movablesupport member that can hold in place the punched out component members;a selectively operable welding power supply being connected between thepressure-welding device and the support device.
 17. An apparatus formanufacturing laminates as set forth in claim 16 wherein a plurality ofthe laminating devices are provided in the feeding direction of theworkpiece; the laminating devices adapted to be operated alternately.18. An apparatus for manufacturing laminates comprising a plurality ofcontinuously formed component members having different cross-sectionalshapes; the component members having outside contours corresponding tothe cross-sectional shapes of the laminate being formed from a sheetmaterial and sequentially laminated into one piece comprising a feedingdevice for indexing a long-size workpiece in the longitudinal direction,a plurality of punch-die sets for forming a plurality of componentmembers with non-separating indentation, with at least part of theoutside contours left unseparated from the workpiece, and a laminatingdevice disposed on the most downstream side in the feeding direction ofthe workpiece for sequentially punching out, laminating the componentmembers into one piece; the laminating device comprising a holdingdevice having a hole for allowing the component members to pass andformed in such a manner as to constrain the downward movement of theworkpiece, a pressure-welding device disposed above the holding deviceand having a vertically movable pressure-welding punch for punching out,laminating and pressure-welding the component members, and a supportdevice provided below the holding device and having a vertically movablesupport member that can hold in place the punched out component members;a plurality of the laminating devices being provided in the feedingdirection of the workpiece and adapted to be operated alternately. 19.An apparatus for manufacturing laminates as set forth in claim 16,wherein the support member descends by an amount equal to the thicknessof the component members and stops at that position every time thecomponent members are laminated and pressure welded by thepressure-welding device.
 20. An apparatus for manufacturing laminates asset forth in claim 16, wherein a punch-die set for forming dowel holesand dowel pins concentrically on the upper and lower surface within theoutside contours of the component members is provided.